Apparatus for processing filament-forming mineral materials and forming and packaging filaments

ABSTRACT

THIS INVENTION RELATES TO A METHOD OF AND APPARATUS FOR PROCESSING HEAT-SOFTENABLE MINERAL MATERIALS, SUCH AS GLASS, AND INVOLVES MELTING AND REFINING BATCH MATERIAL IN ONE MELTING AND REFINING FURNACE TO A HIGH DEGREE OF HOMOGENEITY AND FLOWING THE REFINED GLASS IN A MULTIPLICITY OF PATHS TO DELIVER THE GLASS AT CONTROLLED TEMPERATURES TO A LARGE NUMBER OF STREAM FEEDERS OR BUSHINGS ARRANGED IN TWO PARALLEL ROWS TO FACILITATE SIMULTANEOUS ATTENUATION OF THE GROUPS OF STREAMS FROM THE FEEDERS TO FILAMENTS AND PACKAGING STRANDS OF THE FILAMENTS ON ROTATABLE COLLECTORS. THE METHOD INVOLVES TEMPERATURE AND HUMIDITY CONTROL OF A MOVING AIR ENVIRONMENT AND SUBSTANTIALLY UNIFORM DISTRIBUTION OF THE CONDITIONED AIR WITH RESPECT TO THE STREAM FEEDERS IN THE FORMING ROOM.

. M. L. FROBERG ET AL 3,555,939 APPARATUS FOR PROCESSINGFILAMENT-FORMING MINERAL MATERIALS AND FORMING AND PACKAGING FILAMENTS22, 1967 6 Sheets-Sheec 1 Feb. .9, 1971 Filed Nov.

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Feb. 9, 1971 r M. FROBERG ETAL 3,561,939 APPARATUS FOR PROCESSINGFILAMENT-FORMING MINERAL MATERIALS AND FORMING AND PACKAGING FILAMENTSFiled Nov. 22, 1967 6 Sheets-Sheet 6 waw ATTORNEYS United States PatentQ 3,5i,939 APPARATUS FOR PROCESSING FlLAMENT-FORM- ING MINERAL MATERIALSAND FQG AND PACKAGING FILAI /IENTS Magnus L. Froberg and Roy E. Smith,Newark, Ohio, assignors to Owens-Corning Fiberglas Corporation, acorporation of Delaware Filed Nov. 22, 1967, Ser. No. 685,294 Int. Cl.C0311 37/00 US. Cl. 65-11 Claims ABSTRACT OF THE DISCLOSURE Thisinvention relates to a method of and apparatus for processingheat-softenable mineral materials, such as glass, and involves meltingand refining batch material in one melting and refining furnace to ahigh degree of homogeneity and flowing the refined glass in amultiplicity of paths to deliver the glass at controlled temperatures toa large number of stream feeders or bushings arranged in two parallelrows to facilitate simultaneous attenuation of the groups of streamsfrom the feeders to filaments and packaging strands of the filaments onrotatable collectors. The method involves temperature and humiditycontrol of a moving air environment and substantially uniformdistribution of the conditioned air with respect to the stream feedersin the forming room.

This invention embraces a method of and apparatus for processingheat-softenable mineral materials, such as glass, and more especially toa method and apparatus involving the melting and refining of asubstantial quantity of glass in one furnace or tank to a high degree ofrefinement and homogeneity and flowing the refined glass to a largenumber of individual stream feeders, and attenuating groups of streamsfrom the feeders to continuous filaments under controlled conditionswhereby to render the production of large quantities of filaments moreeconomical through the use of a single glass melting and refiningfacility.

One method that has heretofore been employed in producing continuousfilaments of glass involves the use of marbles or spheres of glass whichare premolded of refined glass, the spheres or marbles of glass beingremelted in a heated feeder or bushing and the streams of glass from theindividual feeder or bushing attenuated to filaments by winding a strandof the filaments on a forming tube of a winding machine. This method isrelatively costly by reason of the marble molding operation, the loss ofheat energy on cooling the marbles and the subsequent reheating of theglass marbles to molten condition suitable for attenuation.

Improvements have been made involving a method of melting and refiningglass whereby the glass is flowed through a channel system resembling anH-shaped configuration with stream feeders arranged along the branchchannels of the H-shaped channel system whereby several groups ofstreams are delivered by the feeders and the groups of streamsattenuated into filaments by winding strands of the filaments oncollector tubes of winding machines. Pat. 3,269,820 discloses a directmelt process of this character wherein refined glass from a melting andrefining furnace or chamber is delivered through channels of a singleH-shaped channel system directly connected with the melting and refiningfurnace. As shown in Pat. 3,269,820 each H-shaped channel systemreceives glass from an individual melting and refining furnace. In orderto provide for substantial production yield of fibers or filaments, itwas necessary to employ a plurality of melting and refining furnaces,each having an H-shaped glass flow channel system.

3,561,939 ?atented Feb. 9, 1971 The present invention embraces a methodof supplying highly refined molten glass from a single melting andrefining furnace or facility to a cross channel and the glassdistributed from the cross channel to a plurality of glass flow paths ofa plurality of H-shaped glass flow channel systems, the glass flow pathsof the pairs of branch channels of the H-shaped configurations being inspaced relation providing two groups of branch channels in alignedrelation and stream feeders disposed along the branch channelsdelivering streams or bodies of glass for attenuation to filaments.

Another object of the invention resides in a method of flowing refinedglass from a single supply along a first rectilinear flow path, thenceflowing the glass from the first flow path in a plurality of spacedstreams normal to the direction of flow of the glass in the first flowpath, and flowing glass from the spaced streams in two laterally spacedpaths substantially parallel with the first flow path and deliveringbodies of glass from the laterally spaced paths for attenuation tofilaments whereby to attain a high yield of filaments from a singleglass supply facility.

Another object of the invention resides in a method of melting glassbatch and refining the molten glass in a chamber, and flowing the moltenglass from the chamber in a supply stream, flowing a plurality of feederstreams of the glass from the supply stream in directions normal to thedirection of flow of the glass in the supply stream, thence flowingbranch streams of glass from the feeder streams in directions normal tothe direction of flow of the feeder streams and delivering groups ofbodies of the glass from the branch streams and controlling thetemperature of the glass of the streams to enable attenuation of thebodies of glass to continuous filaments.

Another object of the invention resides in a glass processing facilityinvolving a melting and refining furnace or facility for processing asubstantial quantity of glass to a highly refined condition, and flowingthe highly refined glass along a glass supply channel or manifold indirections normal to the longitudinal axis of the furnace, anddelivering the glass from the supply channel to groups of branchchannels wherein the channels of each group are arranged in an H-shapedorientation with pairs of the branch channels of each group inlengthwise aligned relation providing two parallel rows of branchchannels, the branch channels being provided with bushings fordelivering groups of glass streams and the streams of each groupattenuated to filaments by winding a strand of the filaments upon arotatable collector individual to each group whereby a large number ofstrands from the groups of filaments is concomitantly wound intopackages whereby to substantially reduce the cost of producing filamentsof glass through the provision of a single glass melting and refiningfurnace for supplying glass to all of the stream feeders.

Another object of the invention embraces the provision of a plurality ofconnected glass fiow channel constructions wherein combustion burnersare arranged in the side walls defining the channels to minimize orreduce erosion of the refractory constituting the channel constructionsand thereby reduce contamination of the glass,

Another object of the invention resides in the provision of vent stacksarranged in spaced relation along a glass supply channel whereby to ventgases from the glass from a multiplicity of connected glass flowchannels receiving molten glass from a melting and refining furnace.

Another object of the invention resides in an arrangement of multipleforehearth or flow channel assemblies of H-shaped configurationreceiving glass from a single supply zone with glass stream feedersarranged along the parallel branches of the H-shaped configurationswherein a group of streams is delivered from each feeder into a;

forming room or chamber, the arrangement including means for deliveringconditioned air into the forming room chamber in a distribution patternand in amounts to effectively convey away the heatfrom the glass streamsand the flow channels with a minimum of turbulence so as to improveattenuation of the streams to filaments and reduce filament break-outs.

Another object of the invention resides in the maintenance of a movingair environment adjacent groups of streams delivered from feedersassociated with glass flow channels arranged in H-shaped orientationinvolving delivery of conditioned air through perforate ceiling areasinto the forming room to establish a substantially uniform airenvironment at the upper region of the forming room, the air beingconditioned through the utilization of an air cooling and humidifyingfacility individual to each H-shaped forehearth or flow channel system,the air flow through the forming room being of a character to avoidturbulence and promote a balanced air environment adjacent and embracingthe groups of streams delivered from the feeders.

Another object of the invention resides in the delivery of air at acontrolled temperature and humidity into the forming room at a rate andamount to assure substantially constant temperature and humidityconditions in the forming room to effectively dissipate the heat loadfrom the glass streams with a minimum of turbulence in the forming room.

Further objects and advantages are within the scope of this inventionsuch as relate to the arrangement, operation and function of the relatedelements of the structure, to various details of construction and tocombinations of parts, elements per se, and to economies of manufactureand numerous other features as will be apparent from a consideration ofthe specification and drawing of a form of the invention, which may bepreferred, in which:

FIG. 1 is a semischematic top plan view showing the melting and refiningfurnace and forehearth and glass distribution channel system orarrangement of the invention;

FIG. 2 is a sectional View taken substantially on the line 22 of FIG. 1illustrating the branch channels of one of the H-shaped flow channelconfigurations, the forming room, strand winding apparatus and meansproviding a conditioned air environment in the forming room;

FIG. 3 is a longitudinal sectional view through one of the branchchannels of an H-shaped forehearth or flow channel configuration, theview being taken substantially on the line 33 of FIG. 1

FIG. 4 is an enlarged detailed sectional view taken substantially on theline 44 of FIG. 3;

FIG. 5 is an enlarged transverse sectional view taken substantially onthe line 55 of FIG. 1;

FIG. 6 is an enlarged fragmentary sectional view taken substantially onthe line 66 of FIG. 1;

FIG. 7 is an enlarged view of the construction of FIG. 5 illustrating aheat dissipating or cooling means disposed beneath a glass flow channelsection;

FIG. 8 is a top plan view of one of the air conditioning anddistributing units for one of the H-shaped flow channel configurations;

'FIG. 9 is a sectional view of a portion of the forming room, the viewbeing taken substantially on the line 99 of FIG. 2;

FIG. 10 is a fragmentary isometric view illustrating the method utilizedfor winding a strand of filaments into a package on a winding machine,and

FIG. 11 is a fragmentary view similar to FIG. 9 illustrating thepackaging of strands of filaments on automatic multiple-collet winders.

Referring initially to FIG. 1 the apparatus and arrangement includes asingle melting and refining furnace or facility 10 in which glass batchis melted and refined to a high degree of homogeneity and the refinedglass flowed from an exit end of the furnace through a con nectingchannel 11 of a main forehearth 12. In the embodiment of the inventionillustrated in the drawings, the glass from the connecting channel 11 isdistributed through a manifold channel or cross channel 14 of aforehearth extension 15 to a plurality of H-shaped forehearth chan nelconfigurations or glass distributing instrumentalities, each of whichreceives molten glass from the cross channel 14.

The connecting or main feed channel 11 with the cross channel 14resembles a T-shaped configuration. The I-I-shaped configurations ofglass flow channels, there being five in number in the illustratedembodiment, are of substantially identical construction and aredesignated 16, 16a, 16b, 16c and 16d. As shown schematically in FIG. 1,the respective pairs of branch channels of the H- shaped configurationsare aligned in two laterally spaced rows in the manner illustrated inFIG. 1 and parallel with the cross channel 14.

Each of the branch channels is equipped with glass stream feedersarranged in the ceiling area of an elongated forming room 20. A strandwinding machine is disposed beneath each feeder, the winding machinesbeing arranged in two parallel rows lengthwise of an elongated windingroom 22 illustrated in FIG. 2.

In the embodiment illustrated, each branch channel of each of theH-shaped forehearth configurations is equipped with five stream feedersproviding a total of one hundred stream feeders, each delivering thegroup or groups of streams which are attenuated to filaments by windingstrands of the filaments on rotating collectors of the winding machines.As shown in FIG. 2, the forming room 20 is contiguous with and above thewinding room 22, the latter containing the strand winding machines, athird room 23 being below the winding room 22.

The melting and refining furance 10 is similar to a: furnace illustratedin Day et a1. Pat. 3,269,820 but is of" a capacity to supply highlyrefined textile glass to all of the H-shaped forehearth constructionsand the stream feeders carried thereby. Through the provision of asingle furnace 10 supplying molten glass to all of the stream feeders,the capacity or size of the furnace enables efiicient refinement of theglass so that a more homogeneous glass is delivered to the streamfeeders and hence break-outs are substantially reduced and production offilaments greatly increased.

As shown in FIG. 1, the furnace 10 includes an elongated generallyrectangular melting and refining chamber or tank 24, the furnaceconstruction being of built-up refractory, the glass containing chamber24 being of greater length than its width, with the average depth ofglass in the furnace during operation being about twenty-five inches ormore. The furnace 10 is supported upon a suitable steel frame structureof conventional construction, a portion of the supporting structurebeing shown at 26 in FIG. 2.

The furnace arrangement includes means 28 for feeding raw batch glass orother heat-softenable fiber-forming: mineral material into the furnacechamber 24 at the rear or stack end of the furance. The batch feeders orchargers- 28 are preferably of the motor driven screw feed type ofconventional construction. Each of the batch chargers receives batchmaterial from a supply (not shown) in a conventional manner.

The end of the chamber 24 adjacent the batch chargers 28 is connectedwith two exhaust stacks 30 and 32, the stacks venting the gases drivenoff or emitted from the glass during melting and refining operations.The operation of the motor driven batch chargers 28 is controlled byconventional means (not shown) responsive to variations in the amount ofglass in the melting and refining chamber 24 so as to maintainsubstantially constant the amount of glass in the chamber.

The furnace chamber 24 is fired or heated by fuel gas or other suitablefuel mixed with air and delivered to rows of combustion burners 36mounted in burner blocks in the respective side walls 38 of the chamber24 above the level of the glass in the chamber. The air, for mixing withthe fuel gas or other fuel delivered to the burners 36, is preheated ina recuperator arrangement (not shown) associated with the stacks 30 and32, the recuperator arrangement being of the general character disclosedin Day et al. Pat. 3,269,820.

Steam or air bubblers, indicated at 39, are provided in the floor of themelting and refining chamber 24 to promote cycling or recirculation ofthe molten glass in the chamber to effect a high degree of refinement ofthe glass before it flows through the exit channel 11 in the connectingforehearth 12. The molten glass is circulated and recirculated Withinthe melting tank or furnace chamber 24 through a distance several timesthe length of the chamber to provide a time-temperature treatment topromote a high degree of homogeneity for the glass prior to its deliverythrough the channel 11.

In the embodiment illustrated the glass from the furnace flows throughchannel 11 to a cross channel 14 contained in an elongated forehearthconstruction 15 extending normal to the forehearth connection 12. Asshown in FIG. 1, the cross forehearth channel member 14 with theconnecting forehearth channel 11 is in the shape of a T configuration.The molten glass delivered to the cross channel 14 flows in oppositedirections therein from its junction from the main feed channel 11.

The main cross channel 14 functions as an elongated manifold, deliveringmolten glass from the cross channel 14 into each of the plurality ofH-shaped forehearth configurations 16, 16a, 16b, 16c and 16d throughfeed channels 48 individual to each forehearth configuration.

Each H-shaped forehearth channel configuration comprises a centralchannel 50 which forms an aligned extension of the adjacent feed channel48, the channels 48 and 50 being disposed normal to the cross channel14. Each H-shaped configuration includes forehearth branch channelsections 52, 53', 54 and 55. As shown in FIG. 1, the the oppositelyextending branch channel sections 52 and 53 of each H-shaped forehearthunit are arranged in aligned end-to-end relation in a direction normalto the direction of the aligned channels 48 and 50 of each I-I-shapedunit.

The pairs of branch channel sections 54 and 55 are spaced laterally fromthe pairs of forehearth sections 52 and 53 and are arranged inparallelism therewith. Thus, as shown in FIG. 1, all of the branchsections 52 and S3 of each H-shaped configuration are in lengthwisealigned relation and parallel with the cross channel 14. The pairs ofbranch channel sections 54 and 55 in aligned end-toend relation areparallel with the cross channel 14.

This arrangement of forehearth branch sections facilitates the use of anelongated forming room or walled chamber 20, the outline plan view ofthe room 22 being indicated in broken lines in FIG. 1 and also shown inFIG. 2, the side walls of the forming room being designated 6i) and 62.Each of the branch channel sections 52, 53, 54 and 55 of each H-shapedforehearth construction is equipped with a plurality of bushings orstream feeders 66, one of which is shown in FIG. 3 and several of thefeeders shown in FIG. 9. Each stream feeder is provided with a pluralityof orifices or openings through which flow streams of glass to beattenuated to filaments.

In the embodiment illustrated, there are five feeders 66 on each of thebranch sections 52, 53, 54 and 55 of each of the H-shaped units 16, 16a,16b, 16c and 16d. With five forehearth H-shaped configurations as shown,there are one hundred bushings or stream feeders 66 arranged in two rowslengthwise or" the elongated forming room each row comprising fiftystream feeders.

The side walls of the H-shaped constructions defining the glass flowchannels are equipped with horizontally disposed combustion burners 118for burning fuel and air mixtures at regions above the glass level ineach of the Channels to maintain the glass in flowable condition fordelivery to all of the bushings or stream feeders 66.

The cross channel forehearth section 15 is provided with a plurality ofvent stacks to facilitate escape of the gases of combustion from theglass flow channels. As shown in FIG. 1, there are four vent stacks orvent means 70, 71, 72 and 73 spaced along the cross channel section 14,a portion of one of the vent stacks 72 being shown in FIG. 2.

Each of the vents or vent stacks is connected with the cross channel 14by a passage 75 to convey away gases from the cross channel 14, theglass flow channels 48 and 5t) and the glass fiow channels in the branchsections of each H-shaped forehearth configuration. Thus, the gases ofcombustion from the regions above the glass in ail of the glass flowchannels are vented or escape through the vent stacks 7G, 71, 72 and 73.

The molten glass near the exit end of the melting and refining furnace1G is at a comparatively hi h temperature of, for example, about 2850 F.It is desirable that the glass be processed in the furnace 11 to acomparatively high temperature so as to refine the glass to a highdegree and rid the glass of gas bubbles so that the glass issubstantially gas free and homogeneous prior to its delivery from thefurnace through the channel 11.

It is essential to exercise effective control of the temerature andhence viscosity of the glass in the cross channel and the branch fiowchannels and to reduce the temperature of the glass so that in the flowchannels of the branch sections 52, 53, 54 and 55, the glass tempera--ture may be maintained, for example in a range of 2250 F. to 235 0 F.The glass temperatures in the branch channels may be varied dependentupon the size of orifices in the stream feeder 66 and the linear speedat which the streams are attenuated to filaments.

Control of the temperature of the glass in the several glass flowchannels is maintained through the employment of combustion burnersarranged along the forehearth sections and branch sections, the burnersbeing adjustable to vary the heating in various regions to maintain theglass in the channels at desired temperatures. In the embodimentillustrated the combustion burners are arranged in the side walls of theforehearth and branch constructions and the products of combustionprojected in generally horizontal directions into the glass fiowchannels.

Arranged along the forehearth connection 12 are horizontally disposedburners 7 8 which are adjustable to control the temperature of the glassin the channel 11. It is desirable that the molten glass in the channel11 be reduced to a temperature, for example, of 2650 F. or a lessertemperature than that of the glass in the exit region of the furnacechamber or tank 24.

The glass flowing through the channel 11 normally loses heat. Theburners 78 are adjusted or regulated so that the heat loss does notbring the temperature of the glass below the desired temperature in thechannel 11.

It is desirable that the temperature of the glass in the cross channel14 be comparatively high so that the glass is of a comparatively lowviscosity or liquidus condition so that the glass readily flows throughthe cross channel 14 to the several H-shaped forehearth channels. Theglass in the cross channel 14 is preferably maintained at or near thetemperature of the glass in the feed channel 11. Burners 80 are arrangedin ports 82 in the side walls of the cross channel construction 1throughout the length of the channel 14, the burners being adjustable tocontrol the temperature of the glass throughout the length of the crosschannel.

This temperature control is essential in order that the glass deliveredfrom the cross channel 14 to the several branch channels 48 is atsubstantially the same temperature in each of the branch channels. Theburners 89 are arranged in substantially horizontal opposed positionswhereby heat energy is projected or delivered horizontally and justabove the level of the glass in the channel 14. Each of the burners 80is equipped with a control valve 84 whereby each burner may beindividually controlled so that the heat may be regulated throughout thelength of the cross channel 14.

It is found that by mounting the burners in opposed relation in the sidewalls of refractory defining the channel, erosion of the refractory isgreatly reduced thereby avoiding contamination of the glass. It shouldbe noted that the region 86 above the glass channel 14 of the crosschannel construction 15 is of substantial volume to facilitate flow ofthe gases of combustion to the vents 70, 71, 72 and 73 from the channel14 and the gases from the channels 48, 50 and the branch channels 52,53, 54 and 55 of the respective H-shaped channel systems orconfigurations.

The burner control valves 84 may be of the manual control type or of theconventional solenoid-actuated type automatically controlled bythermocouples 87 extending into the glass in the channel 14 at spacedpositions along the channel, one of the thermocouples being shown inFIG. 6. The refractory walled channels 48 and 50, extending normally tothe lengthwise axis of channel 14, are of a character similar to therefractory construction defining the cross channel 14. FIG. is asectional view through the glass flow channel 50 illustrating therefractory construction 90 defining the channel.

The glass fiow channel 50, as will be seen from FIG. 5, is of a lesserdepth than the depth of the cross channel 14 as the amount of glassfiowing through the channels 48 and 50 need only be sufiicient to supplythe stream feeders disposed along the branch channels 52, 53, 54 and 55of each of the H-shaped channel systems.

The side walls of the forehearth section 90 of refractory defining thechannels 48 and 50 are fashioned with horizontally arranged ports 92 inthe opposed walls, each port being equipped with burners 94 for heatingthe glass in the channel 50.

The burners 94 are controlled by valves 96 which may be of the manuallyoperated type as shown or of the solenoid-operated type controlled bythermocouples 97 spaced lengthwise in one of the side walls andextending into the glass in the channel 50. The region 98 provided abovethe glass channel 50 is of substantial volume to accommodate flow ofgases of combustion toward the vent stacks associated with the crosschannel 14.

The construction of refractory defining the glass channel 48 is similarto that shown in FIG. 5 but a glass flow channel 48 is preferably ofslightly greater depth than channel 50 as it accommodates glass flow forthe four branch channel sections of an H-shaped configuration.Combustion burners 94 and control valves therefor are arranged inopposite side walls of the refractory defining the glass channel 48 formaintaining the glass therein at the desired temperature.

FIG. 3 is a longitudinal sectional view through one of the forehearthbranch channel sections 55. FIG. 3 is exemplary of the construction ofeach of the branch channels 52, 53, 54 and 55 of each H-shapedglass-flow channel configuration illustrated in FIG. 1. Each branch construction is fashioned with a glass flow channel 110 defined by walls ofrefractory.

The fioor 112 is fashioned with lengthwise spaced throats or passages114 to accommodate flow of the glass from the channel 110 into streamfeeders 66 disposed in registration with the passageways 114, one of thestream feeders being illustrated schematically in FIG. 3.

Each of the stream feeders 66 is provided with a plurality of orificesthrough which flow fine streams of glass for attenuation to filaments.As shown in FIG. 3, a branch channel 55 is fashioned with fivepassageways 114, each equipped with a stream feeder or bushing 66. Thebranch channel sections 52, 53 and 54 are substantially identical withthe channel section 55 in each of the five H-shaped forehearth channelconfigurations, and each branch channel is equipped with five bushings66.

Each of the side walls of the branch channel sections u is provided witha plurality of horizontally disposed ports 116, each accommodating acombustion burner 118 for delivering intensely hot gases of combustioninto the region 120 above the glass fiow channel 110. Each of theburners 118 is equipped with a control valve 122 for regulating theburners. As mentioned in reference to the burner control valves 84 and69, the control valves 122 may be of the conventional solenoid-actuatedtype controlled'by thermocouples 123 extending through side walls of thebranch sections into the glass in the glass flow channels, onethermocouple being shown in FIG. 4.

The controlled burners 118 are disposed throughout the length of eachbranch channel section 52, 53, 54 and 55 of each H-shaped unit in orderto maintain substantially constant the temperature of the glass in theglass fiow channel 110.

The regions 120 above the glass flow channels 110 are of substantialvolume so as to accommodate the flow of gases of combustion to the ventstacks 70, 71, 72 and 73 associated with the cross channel 14.

Thus, the combustion gases from all of the burners 78, 80, 94 and 118are exhausted through the vent stacks. Through this method, theintensely hot products of combustion are continuously conveyed away fromthe glass flow channels facilitating the maintenance of a more coolenvironment in the forming room 20.

The invention is inclusive of a method and arrangement for establishingand maintaining a moving air environment for the substantially closedforming room 20 providing for improved distribution of moving air, theair being conditioned to a desired temperature and relative humidity toassure a constancy of air flow through the forming room with a minimumof turbulence and thereby facilitate improved attenuation with a minimumof filament break-outs, and the forming room continuously purged offilament fragments, fuzz or other foreign particles.

FIGS. 2, 8 and 9 illustrate the system or arrangement for conditioningand distributing air through the ceiling area of the forming room 20 andthe arrangement of winding machines in the winding room 22 forcollecting and packaging strands of filaments attenuated from glassstreams flowing from the stream feeders 66.

FIG 2 is a sectional view through the forming room 20 and the windingroom 22, and illustrating the branch channel sections 53 and 54 definingthe glass flow channels 110 disposed at the region of the ceiling of theforming room 20.

The streams of glas from the feeders 66 are attenuated into filaments126 which are converged into strands 128, sprays of water beingdelivered onto the filaments from spray nozzles 121. The groups offilaments engage applicators 130 of conventional construction andreceive therefrom a coating or size as is conventional in processingfilaments of glass, the strand 128 being wound upon a forming tube 132mounted on a collet 134 of a winding machine disposed in the windingroom 22, there being a winding machine disposed beneath each of thestream feeders 66. The winding machines are arranged in two rows alignedlengthwise of the winding room 22.

The winding machines 136, provided beneath the aligned feeders 66mounted on the branch channel sections 52 and 53, constitute one row ofwinding machines. The winding machines 138 disposed beneath the streamfeeders 66 of the branch channel sections 54 and 55 constitute a secondrow of winding machines arranged lengthwise in the winding room 22.Through this arrangement comparatively few operators are required in thewinding room 22 to doif completed strand packages from the collets 134,affix empty forming tubes $132 to the collets and initiate winding onthe empty forming tubes.

During winding of the strands 128 on the forming tubes 132, each strandis oscillated by a traverse oscillator 140 mounted upon a reciprocableand rotatable shaft 142. The rotating traverse oscillator 140 effectscrossing of individual convolutions of strand 12 8 as the strand iswound in a package. The rotatable bar or shaft 142 carrying the traverse140 is reciprocable lengthwise of a collet 134 to distribute the strandlengthwise on the forming tube in a conventional manner to form apackage.

The strands 128 pass downwardly through elongated slots !146 in thefloor 148 of the forming room 20 and are wound on the forming tubes 132.Arranged substantially parallel with the path of movement of the strands128 are chutes 150 of planar shape, there being a chute 150 beneath eachof the stream feeders 66, as shown in FIG. 9. The upper ends of thechutes 150 are anchored upon members or rods 152 extending across theslots 146. The regions of the slots adjacent the anchor members 152 maybe provided with bafiies or restrictions 154 to increase the velocity ofair movement downwardly through the slots adjacent the strands 128.

The lower ends of the chutes extend into openings 156 in the floor 158of the package winding room 22. The chutes i150 serve to direct airmovement along the advancing strands 128 and to dispose of waste glassduring the periods of interruption of attenuation to doif the completedpackages and mount empty forming tubes on the collets. The chutes 150direct the waste glass through the openings 156 into suitable containers(not shown) disposed in the room 23.

Arranged at each side of the branch channel sections 52, 53, 54 and 55are metal gratings 162 which provide a floor of a service aisle at eachside of each of the forehearth branch channels for purposes ofinspection and maintenance, two of the gratings being shown at the sidesof the channels 53 and 54 in FIG. 2.

The arrangement for conditioning air for the air environment in theforming room 20 and the duct system or arrangement for delivering anddistributing conditioned air through the ceiling area of the formingroom is illustrated in FIGS. 2, 8 and 9. One of the features of the airenvironment system is the provision of an air conditioning anddistribution construction or arrangement individual to each of theH-shaped flow channel forehearth constructions 16, 16a, 16b, 16c and16d. Disposed above the central region of the forming room ceiling areair delivery hoods or ducts 164 and 164a. Disposed adjacent the walls 60and 62 above the ceiling of forming room 20 are hoods or ducts 166 and166a.

An air conditioning instrumentality or unit 170 is disposed in theposition shown in FIGS. 2 and 8. Each of the air conditioning units 170is of a conventional character which cools, filters or conditions theincoming air to a desired temperature through the delivery of watersprays into the air moving through the unit and establishes a relativehumidity approaching or attaining 100% in the air to be delivered intothe forming room. The air conditioning unit 170 embodies filter means(not shown) and spray nozzles 171 for projecting moisture into theincoming air, and a rotatable motor-driven blower 173 moving the airthrough the unit 170 to effect delivery of conditioned air into theforming room 20 at the desired rate or volume.

A conventional unit suitable for the purpose is marketed under the tradename Rotospray. As shown in FIG. 8, each air conditioning unit 170 isequipped with an air inlet pipe 172 for admitting atmospheric air to theunit.

A valve or damper 174 is disposed in the pipe 172 to control theadmission of atmospheric air. The conditioned air from the unit 170 isdelivered into 'a central pipe or manifold 176 and the air in themanifold delivered through pipe 178 which are connected with the airdelivery ducts or hoods as shown in FIGS. 2, 8, and 9. The air istreated in each conditioning unit 170 so that the air entering theforming room 20 from the hoods or ducts 164, 164a, 166 and 166a is at atemperature of about 60 F. and as near as practicable in a saturatedcondition, that is, a dew point of 60 F.

Each unit 170 includes filter means for cleaning the air prior to itsdelivery into the forming room. Each air conditioning unit deliverssprays of water into the air moving through the conditioning unit topromote saturation of the air. Disposed in the lower room 23 is a likenumber of conditioning units 170a of the same character as the units 170for the purpose of spraying water into the air exhausted from the rooms20 and 22 to cool the air and filter or wash the air to remove foreignmatter, broken filaments or fuzz that may be present in the air movinginto the room 23 through the floor passages or slots 146 and 156.

As shown in FIG. 2, each of the air delivery ducts or hoods is equippedwith an air diffuser or distributor 182 for diffusing and dispersing theair in the hoods. The exit of each of the hoods is provided withperforated ceiling members 184 and 184a which may be provided withdeflectors 185 to assist in distributing the air so that the airdelivered through the perforated members 184 and 184a is distributedsubstantially uniformly throughout the ceiling area occupied by themembers.

It should be noted that the groups of streams of glass from the feeders66 carried by the branch flow channels are spaced substantial distancesfrom the walls 60 and 62 of the room 20 so that the amount of airdelivered through the perforate members 184 and 184a is in substantiallyproportionate volumes at the regions laterally of each row of streamfeeders 66. The units 170 and 170a embody air blowers for effectivecirculation of air through the forming room 20 at comparatively lowvelocities at the ceiling air delivery regions so that adequate volumesof moving air are maintained at the opposite sides of the rows ofstrands of filaments to effectively convey away the heat load from theforehearth constructions, the stream feeders and the glass and thusprovide an improved air environment in the forming room with a minimumof air turbulence.

By establishing substantially uniform velocity of air embracing theglass streams at the regions of attenuation of the filaments 126, thereis a marked reduction in the occurrence of filament break-outs as theair in the attenuating environment is more stable through this improvedmethod of distributing air throughout the available ceiling area intothe forming room.

The direction of air delivered through the left-hand ducts 164 and 166,as viewed in FIG. 2, is deflected during its downward movement throughthe forming room 20 toward the adjacent slots 146, the movement of theair carrying with it any foreign particles, dust, broken filaments orfuzz so that the forming room is being continuously swept by generallydownwardly moving air. A similar air environment is developed throughthe delivery of air at the right-hand ceiling area through the ducts164a and 166a, the air moving generally downwardly from the ducts 164aand 166a and converged toward the passages :26 beneath the forehearthbranch constructions 54 and The air exhausted from the lower room 23through the air filtering units 170a may be recirculated in whole or orin part through the air conditioning units 170, or part or all of theexhaust air from room 23 may be delivered to the atmosphere, in whichevent the dampers or valves 174 would be opened fully to admitatmospheric air to the units 170. Connected with each unit 170a is aduct or pipe 188 which is joined with the adjacent pipe 172, as shown inFIG. 2. An exhaust air pipe 190 is connected with each of the pipes 188.

Disposed in each pipe 188 between the connection of pipe 188 with pipes172 and 190 is a valve or damper 192 which is adjustable to proportionthe amount of exhaust air moving through a unit 170a admitted to a unit170 for recirculation through the rooms 20, 22 and 23. Disposed in theexhaust duct 190 is an adjustable valve or damper 194 to regulate thedelivery of exhaust air to the atmosphere.

If it is desired to admit only atmospheric air to a conditioning unit170, the valve 174 is adjusted to full open position, the valve 194 inthe exhaust pipe 190 moved to full open position, and the adjustablevalve 192 maintained in fully closed position. If it is desired torecirculate some of the exhaust air mixed with fresh incomingatmospheric air, the valves 174, 192 and 194 may be adjusted orregulated to vary the proportion of exhaust air for recirculationthrough the system. The units 170 and 170a contain air moving means orblowers of substantial air moving capacity.

It is found that efficient operating conditions and effectivedissipation of the heat load in the forming room 20 is attained byproviding a volumetric change of air for each stream feeder of at least1000 cubic feet of air per minute and preferably upwards of 1200 or morecubic feet per minute and the air exhausted through the unit 170a atabout the same volume per unit of time.

It is found preferable to operate the air exhaust units 170a to move aslightly higher volume of air per unit of time than the units 170 totake care of air leakage such as encountered in opening access doors 195to the forming room 20, shown in broken lines in FIG. 1, the windingroom 22 and the lower room 23 to assure continuous downward movement ofair through the forming room 20 to render stable the air environment inthe forming room 20. It is found desirable, in order to'satisfactorilyconvey away heat, to deliver air into the forming room 20 in a volume toattain at least two changes of air per minute.

To maintain effective control of the dissipation of the heat load in theforming room 20, it is preferable to mask or shield the gratings ormembers 162 disposed at the opposite sides of each of the forehearthbranch constructions as well as to shield the regions beneath the glassflow branch channel sections. As shown in FIG. 2, a fluid cooled panelmeans 198 is disposed beneath each of the branch channel constructionsand the gratings 162, there being two panels, one at each side of eachrow of stream feeders 66.

The panels 198 are of conventional construction, being fashioned withfluid conveying channels through which water or other suitable fluid iscirculated to impede transfer of heat from the forehearth constructionsand the glass in the channels into the forming room. Water cooled panelsof this character are usually referred to as Dean panels. Through theuse of panels 198, the temperature in the forming room 20 may be moreeasily controlled.

FIG. 7 is a view similar to FIG. illustrating the glass flow channel 50defined by the refractory construction 49, the view illustrating afluid-cooled panel construction 202 disposed beneath the refractory 49and forming a region of the ceiling area of the forming room 20. Thepanel 202 is of the same general character as the panels 198, shown inFIG. 2, the panel 202 being fashioned with fluid conveying channels foraccommodating circulating water or other fluid to assist in conveyingaway heat at the region of the refractory construction 49. The portionof the refractory construction disposed within the forming room 20defining the flow channel 48 is equipped with a similar cooling panel toassist in reducing, insofar as is practicable, the transfer of heat fromthe forehearth refractory constructions into the forming room 20.

Means are provided in the forming room 20 for illumination. Disposed atthe central region of the ceiling area are electrically energizablelamps 206 of conventional construction supported by a member 208suspended by conventional means (not shown). The winding room 22 islikewise equipped with electrically energizable lamps 210.

As shown in FIG. 9, the winding machines illustrated are of the singlecollet type wherein the strands 128 are wound on forming tubes 132 informing strand packages. When a package is completed on a collet 134,the collet drive motor 139 shown in broken lines in FIG. 2, isdeenergized, either automatically or by operator controlled switchmeans. The collet and package are brought to rest and mechanicalattenuation of the filaments 126 from glass streams of the adjacentstream feeder is thus interrupted.

During the period in which the operator dotfs the completed package andtelescopes a fresh or empty forming tube 132 onto the collet, thestreams of glass from the feeder fall by gravity along the chute 150 andare guided by the chut into a suitable container (not shown) disposed inthe lower room 23. Attenuation is again initiated by the operator bymanually winding a strand 128 around an end region of the forming tubeor mandrel and the motor 139 energized. When the collet is brought up toattenuating speed, the strand 128 is moved into engagement with thetraverse member 140 and winding of a package is begun in a well knownconventional manner.

The foregoing described method and arrangement involving multipleH-shaped configurations of glass flow channels receiving glass from asingle furnace or supply makes possible the use of a melting andrefining furnace of substantial size accommodating recirculation of theglass to provide a highly refined homogeneous glass suitable forattenuation to fine filaments. The horizontally disposed combustionburners spaced along the several glass flow channels provide for theexercise of accurate temperature control and hence viscosity of theglass in all regions of the forehearth channels.

The gases of combustion from the burners and gases emitted from theglass in the flow channels are exhausted through the vents 70, 71, 72and 73. The provision of a unitary air conditioning and air circulatingsystem and apparatus individual to each H-shaped forehearth constructionfosters improved temperature and humidity con trol in the forming roomand maintains air movement in the forming room effective to convey awaythe heat load and purge the forming room of broken filaments, fuzz orother foreign particles.

The slots or passages 146 are of a size so that the downwardly movingair from the forming room 20 moves through the passages at a velocity ofabout 500 feet per minute at the region of the passages whereby the airsweeps or purges the room continuously.

FIG. 11 is illustrative of the use of the apparatus with automaticwinding machines for automatically winding the strands into packageswithout interrupting mechanical attenuation of the streams of glassfilaments. An automatic Winding method and arrangement of this characteris shown in Smith Pat. 3,109,602. As shown in FIG. 11, the filaments126a are converged into strands 128a, each strand being wound into apackage on an automatic winding machine 214. Each of the automaticwinding machines is equipped with an indexible turret 216, each turretjournally supporting three collets 218, 219 and 220 rotated by motorsindividual to each collet.

The collet 218 is at the winding station and the strand 128a is beingwound on the forming tube mounted on the collet 218, the strand beingoscillated and traversed lengthwise of the package by an oscillatortraverse 140a mounted on a reciprocable and rotatable traverse bar 142a.As disclosed in Smith Pat. 3,109,602, the rotation of the collets andthe indexing of the turret 216 are programmed so that upon completion ofa package on the collet 218, the collet 218 and completed package aremoved to the position occupied by collet 219 while the collet 220,mounting a fresh forming tube, is moved into winding position andwinding initiated thereon.

The completed package, moving to the position previously occupied bycollet 219 causes the strand to be broken and the advancing strand toadhere to the forming tube on collet 220. When the completed packageceas es rotation, the operator doffs the completed package and mounts afresh forming tube upon the collet 218. As the operations are fullyautomatic there is no interruption of mechanical attenuation of thefilaments 126a. Each chute 150a serves to direct filaments or glassbodies falling by gravity to a suitable collector in the room 23 should13 an interruption occur in the operation of an adjacent automaticwinding machine.

It is apparent that, within the scope of the invention, modificationsand diflerent arrangements may be made other than as herein disclosed,and the present disclosure is illustrative merely, the inventioncomprehending all variations thereof.

What is claimed is:

1. Apparatus for processing glass comprising a single melting andrefining furnace, means for feeding glass batch into the furnace, aforehearth passage in communication With the outlet end of the furnacethrough which molten glass flows from the furnace, a cross chanme], saidforehearth passage being in communication with the cross channelsubstantially at the midregion of the cross channel, the cross channelreceiving molten glass from the forehearth passage, the glass in thecross channel flowing in opposite directions from the junction of thecross channel with the forehearth passage, a plurality of Spaced glassfeed channels in parallel relation connected with the cross channel anddisposed normal to the cross channel, an H-shaped glass flow channelconfiguration connected with each of the spaced feed channels andreceiving molten glass therefrom, the pairs of spaced branch channels ofthe H-shaped channel configurations being in end-to-end aligned relationproviding two rows of branch channels, the outer ends of the branchchannels being unvented, a plurality of orificed feeders arranged alongeach of the branch channels for flowing groups of streams, of glass fromthe feeders, burner means disposed along the cross channel and the feedchannels and the branch channels applying heat to the glass in thechannels, and a plurality of vent stacks disposed in spaced relationlengthwise of the cross channel and in communication with the crosschannel for venting combustion gases from the channels.

2. Apparatus for processing glass and forming fibers therefromcomprising, in combination, a single melting and refining furnace, aforehearth channel connected with the furnace providing a single exitchannel for flowing refined molten glass from the furnace, a crosschannel, the forehearth channel being connected with a midregion of thecross channel, the cross channel receiving molten glass from theforehearth channel, the glass flowing in the cross channel in oppositedirections from the region of connection of the forehearth channel withthe cross channel, a plurality of spaced feeder sections extending fromone side of said cross channel and normal thereto, each feeder sectionhaving a glass flow channel in communication with the cross channel andreceiving molten glass from the cross channel, an H-shaped sectionconnected with each of the feeder sections, the pairs of branch sectionsof each H-shaped section having glass fiow channels receiving glass fromthe adjacent feeder channel, combustion burner means for applying heatto the glass in the glass flow channels, a plurality of vent stacksdisposed in spaced relation lengthwise of the cross channel and incommunication with the cross channel, the cross channel and feederchannels and channels in the branch sections of each H-shaped sectionbeing of suflicient volume to conduct the gases of combustion to thevent stacks, the pairs of branch sections of the H- shaped sectionsbeing in end-to-end aligned relation providing two rows of branchsections, a plurality of orificed feeders arranged along each branchsection for flowing groups of streams of glass from the feeders, anelongated walled chamber embracing the groups of streams of glass 4. Thecombination according to claim 2 including five H-shaped sections withthe feed channel of the central H-shaped section being substantially inalignment with the forehearth channel extending from the furnace, and avent stack disposed adjacent the junction of each of the 15 feedchannels of the other H-shaped sections with the cross channel.

5. Apparatus for processing glass and forming filaments therefromcomprising, in combination, a single melting and refining furnace, aforehearth providing a single channel for flowing refined molten glassfrom the furnace, a cross channel section having connection at itsmidregion with the forehearth channel and receiving molten glass fromthe forehearth channel, a plurality of spaced feeder sections extendingnormal to said cross channel section, each feeder section having a glassfiow channel in communication with the cross channel, an H- shapedsection connected with each of the feeder sections, the pairs of branchsections of each H-shaped section having glass flow channels receivingmolten glass from the adjacent feeder channel, the pairs of branchsections of the H-shaped sections being disposed in end-to-end alignedrelation providing two rows of branch sections, the outer ends of thebranch sections being closed, a plurality of combustion burners disposedin lengthwise spaced relation in the side walls of the sections definingthe glass fiow channels and above the level of the glass in saidchannels, a plurality of vent stacks disposed in spaced relationlengthwise of the cross channel and in communication with the crosschannel, the cross channel and feeder channels and channels in thebranch sections of each H-shaped section being of sufflcient volume toconduct the gases of combustion to the vent stacks, a plurality oforificed feeders arranged along each branch section for flowing groupsof streams of glass from the feeders, an elongated walled forming roomembracing the streams from all of the feeders, a winding room beneaththe forming room, and a plurality of winding machines disposed in thewinding room arranged to wind strands of the groups of filamentsattenuated from the groups of streams into packages.

References Cited UNITED STATES PATENTS 3,231,357 1/1966 Pither 65134X3,271,122 9/1966 Denniston et al 65-12X 3,304,163 2/1967 Holschlag65-12X 3,406,021 10/1968 Day et al. 651

FOREIGN PATENTS 689,297 3/1953 Great Britain -1 S. LEON BASHORE, PrimaryExaminer R. L. LINDSAY, JR., Assistant Examiner US. Cl. X.R.

